JP6124561B2 - Composite repair methods - Google Patents

Composite repair methods Download PDF

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Publication number
JP6124561B2
JP6124561B2 JP2012253983A JP2012253983A JP6124561B2 JP 6124561 B2 JP6124561 B2 JP 6124561B2 JP 2012253983 A JP2012253983 A JP 2012253983A JP 2012253983 A JP2012253983 A JP 2012253983A JP 6124561 B2 JP6124561 B2 JP 6124561B2
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composite material
support wall
repair
frustum
sealing plate
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JP2014100847A (en
Inventor
利和 重冨
利和 重冨
正好 須原
正好 須原
守正 石田
守正 石田
修平 武藤
修平 武藤
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Mitsubishi Aircraft Corp
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Mitsubishi Aircraft Corp
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Priority to JP2012253983A priority Critical patent/JP6124561B2/en
Priority to US14/079,952 priority patent/US9365282B2/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B64AIRCRAFT; AVIATION; COSMONAUTICS
    • B64CAEROPLANES; HELICOPTERS
    • B64C3/00Wings
    • B64C3/26Construction, shape, or attachment of separate skins, e.g. panels
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C73/00Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
    • B29C73/04Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using preformed elements
    • B29C73/06Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using preformed elements using plugs sealing in the hole
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C73/00Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
    • B29C73/04Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using preformed elements
    • B29C73/10Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using preformed elements using patches sealing on the surface of the article
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C73/00Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
    • B29C73/24Apparatus or accessories not otherwise provided for
    • B29C73/26Apparatus or accessories not otherwise provided for for mechanical pretreatment
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B64AIRCRAFT; AVIATION; COSMONAUTICS
    • B64FGROUND OR AIRCRAFT-CARRIER-DECK INSTALLATIONS SPECIALLY ADAPTED FOR USE IN CONNECTION WITH AIRCRAFT; DESIGNING, MANUFACTURING, ASSEMBLING, CLEANING, MAINTAINING OR REPAIRING AIRCRAFT, NOT OTHERWISE PROVIDED FOR; HANDLING, TRANSPORTING, TESTING OR INSPECTING AIRCRAFT COMPONENTS, NOT OTHERWISE PROVIDED FOR
    • B64F5/00Designing, manufacturing, assembling, cleaning, maintaining or repairing aircraft, not otherwise provided for; Handling, transporting, testing or inspecting aircraft components, not otherwise provided for
    • B64F5/40Maintaining or repairing aircraft
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C73/00Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
    • B29C73/24Apparatus or accessories not otherwise provided for
    • B29C73/26Apparatus or accessories not otherwise provided for for mechanical pretreatment
    • B29C2073/264Apparatus or accessories not otherwise provided for for mechanical pretreatment for cutting out or grooving the area to be repaired
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C73/00Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
    • B29C73/24Apparatus or accessories not otherwise provided for
    • B29C73/26Apparatus or accessories not otherwise provided for for mechanical pretreatment
    • B29C2073/268Apparatus or accessories not otherwise provided for for mechanical pretreatment for drilling holes in the area to be repaired
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • B32B37/1009Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure using vacuum and fluid pressure
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00Ancillary operations in connection with laminating processes
    • B32B38/10Removing layers, or parts of layers, mechanically or chemically
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/20Patched hole or depression

Description

本発明は、複合材の修理方法に関する。また、修理された複合材にも関する。   The present invention relates to a method for repairing a composite material. It also relates to repaired composite materials.

航空機の翼の外表面を形成する外板(スキン)は、炭素繊維強化樹脂(CFRP:carbon fiber reinforced plastics)などで形成された複合材が用いられている。その複合材は、複数のCFRPシートが積層されて構成されている。
外板は、翼の表裏に間隔をおいて配置され、翼の前縁および後縁を形成するスパーと共にボックス状に組み立てられている。ボックスの内部は、表裏の外板を支持するリブが設けられるとともに、各種の装置や燃料の収容空間とされている。
ところで、外板が衝撃を受けて損傷すると、修理が必要となる。その修理では、衝撃により層間が剥離している損傷部を除去し、除去により形成される凹部を複合材で埋める。この修理は、ボックス状の構造体を分解せずに行いたい。
A composite material formed of carbon fiber reinforced plastics (CFRP) or the like is used for an outer plate (skin) that forms the outer surface of an aircraft wing. The composite material is configured by laminating a plurality of CFRP sheets.
The outer plate is spaced from the front and back of the wing and is assembled in a box shape with spars that form the leading and trailing edges of the wing. The inside of the box is provided with ribs for supporting the outer plates on the front and back sides, and serves as a housing space for various devices and fuel.
By the way, if the outer plate is damaged by impact, repair is required. In the repair, the damaged portion where the layers are separated by impact is removed, and the recess formed by the removal is filled with the composite material. I would like to perform this repair without disassembling the box-like structure.

損傷部が外板の裏側に到達していなければ、構造体を分解せずに外板表面側(片側)からのアクセスにより修理できる。
例えば、損傷部が表面側から除去されることで形成される凹部に、外板本体と同様の複合材であって半硬化の状態の修理材をフィルム状の接着剤の上から配置する。そして、表面側からの真空引きにより修理材と複合材とを接着フィルムを介して密着した状態としてから、修理材を加熱して硬化させると、複合材に修理材を接着することができる。複合材の凹部は、応力集中を避けるために、全方位に均等な形状をしていることが好ましく、スカーフ加工により平面視円形のすり鉢状に形成されている。
If the damaged part does not reach the back side of the outer plate, it can be repaired by accessing from the outer plate surface side (one side) without disassembling the structure.
For example, a repair material, which is a composite material similar to the outer plate body and is semi-cured, is disposed on the film-like adhesive in the recess formed by removing the damaged portion from the surface side. Then, after the repair material and the composite material are brought into close contact with each other through the adhesive film by evacuation from the surface side, the repair material can be bonded to the composite material by heating and curing the repair material. The concave portion of the composite material preferably has a uniform shape in all directions in order to avoid stress concentration, and is formed in a mortar shape having a circular shape in plan view by scarf processing.

一方、損傷部が外板の裏面側にまで及んでいると、その損傷部が除去されることで形成される凹部が複合材を厚み方向に貫通し、表面側と裏面側との双方に開口する貫通孔が形成されるので、真空引きにあたり裏面側も塞ぐ必要がある。それには、裏面側に作業者を配置することとなるが、作業者が入れるスペースがボックスの内部になければ、構造体を分解せざるを得ない。
非特許文献1では、貫通孔の裏面側を塞ぐために、貫通孔およびそれを塞ぐパッチを楕円形とすることが記載されている。貫通孔およびパッチをほぼ同じ径の円形とする場合とは異なり、貫通孔の長軸にパッチの短軸が沿うようにしてパッチを立てれば、複合材の裏面側にもぐらせることができる。そして、裏面側で回転させたパッチによって、貫通孔の裏面側を封止する。つまり、分解しなくても、複合材の表面側からの真空引きを行う修理が可能となる。
On the other hand, when the damaged part extends to the back side of the outer plate, the recess formed by removing the damaged part penetrates the composite material in the thickness direction and opens on both the front side and the back side. Since the through-hole to be formed is formed, it is necessary to close the back surface side when evacuating. For this purpose, an operator is placed on the back side, but the structure must be disassembled if there is no space for the operator in the box.
Non-Patent Document 1 describes that in order to close the back surface side of the through hole, the through hole and the patch that closes the through hole have an oval shape. Unlike the case where the through-hole and the patch are circular with substantially the same diameter, if the patch is erected so that the major axis of the through-hole is aligned with the minor axis of the patch, the patch can be moved to the back side of the composite material. And the back surface side of a through-hole is sealed with the patch rotated on the back surface side. That is, repair without evacuation can be performed by evacuation from the surface side of the composite material.

Aircraft Icing Handbook,Report#DOT/FAA/AR−08/54 Composite Maintenance and Repair IssuesAircraft Icing Handbook, Report # DOT / FAA / AR-08 / 54 Composite Maintenance and Repair Issues

非特許文献1の手法によれば、損傷部を除去することで複合材に形成される貫通孔を楕円形とする必要がある。しかし、この手法では、楕円形の貫通孔を形成する加工に手間と時間が掛かる。また、楕円の長軸の方向を決めるのに、各製品における修理箇所の強度検討を行う必要があるため、修理に着手するまでにも時間を要する。
以上より、楕円形状とする手法を採用するのは難しい。
According to the method of Non-Patent Document 1, it is necessary to make the through-hole formed in the composite material elliptical by removing the damaged portion. However, in this method, it takes time and labor to form the elliptical through hole. Moreover, since it is necessary to examine the strength of the repaired part in each product in order to determine the direction of the major axis of the ellipse, it takes time to start repairing.
From the above, it is difficult to adopt the technique of making an ellipse.

本発明は、上記のような課題に基づいてなされたもので、複合材の厚み方向全体に損傷が及んでいる場合の片側からのアクセスによる現実的な修理方法を提供することを目的とする。   The present invention has been made based on the above problems, and an object thereof is to provide a practical repair method by access from one side when the entire thickness direction of the composite material is damaged.

本発明の複合材の修理方法は、繊維および樹脂により形成された板状の複合材において裏面側から表面側に向けて拡径する錐台状の範囲を除去し、複合材と、除去された部分に代わる修理材とを接着する。
本発明の修理方法は、除去ステップと、裏面側封止ステップと、錐台状の範囲が除去された複合材に、接着剤を介在させて修理材を配置する修理材配置ステップと、表面側を封止して真空引きする真空引きステップと、を備える。
本発明は、除去ステップでは、錐台の頂面の周縁部から径方向内側に突出する支持壁を残して、頂面から、錐台の底面における頂面の投影領域までを含む範囲を表面側から厚み方向に貫通して除去し、封止ステップでは、除去により形成される貫通孔に表面側から挿入された封止板を支持壁に設置することで裏面側を封止することを特徴とする。
The method for repairing a composite material according to the present invention removes a frustum-shaped range that expands from the back surface side to the front surface side in a plate-shaped composite material formed of fibers and resin, and the composite material is removed. Glue the repair material to replace the part.
The repair method of the present invention includes a removal step, a back surface side sealing step, a repair material placement step of placing the repair material with an adhesive interposed in the composite material from which the frustum-shaped range is removed, and the front surface side. And evacuating step for sealing and evacuating.
According to the present invention, in the removing step, a range including the range from the top surface to the projection area of the top surface at the bottom surface of the frustum is left on the surface side, leaving a support wall protruding radially inward from the peripheral portion of the top surface of the frustum. In the sealing step, the back surface side is sealed by installing on the support wall a sealing plate inserted from the front surface side into the through-hole formed by the removal. To do.

本発明によれば、複合材の片面側(表面側)のみから修理を行える。本発明では、修理の作業者が向き合う複合材の一面側を表面側といい、その反対側を裏面側という。
本発明では、複合材の裏面側に位置する支持壁を残して、複合材から損傷部を除去し、その支持壁に封止板を設置することで、除去により貫通された複合材の裏面側を封止している。このため、裏面側を封止するために、従来手法のように楕円形状の貫通孔を形成し、その貫通孔からパッチをもぐらせて複合材の裏面側に貼り付ける必要がない。このため、本発明では、貫通孔の形状を汎用的な加工で足りる真円とすることができるので、楕円長軸の向きを設定するための強度検討や繁雑な楕円加工が不要となる。これにより、修理時間を短縮できるとともに、修理に要するコストを抑えられる。
以上により、厚み方向全体に損傷が及んでいる複合材の修理にあたり、裏面側に作業者が入れるスペースがなくても、構造体を分解することなく修理できるので、コストを抑えて修理を実施できる。
According to the present invention, repair can be performed only from one side (front side) of the composite material. In the present invention, one side of the composite material that the repair operator faces is called the front side, and the opposite side is called the back side.
In the present invention, leaving the support wall located on the back side of the composite material, removing the damaged portion from the composite material, and installing a sealing plate on the support wall, the back side of the composite material penetrated by the removal Is sealed. For this reason, in order to seal the back surface side, it is not necessary to form an elliptical through-hole as in the conventional method, and to apply the patch from the through-hole to the back surface side of the composite material. For this reason, in this invention, since the shape of a through-hole can be made into the perfect circle which can suffice with general-purpose processing, the strength examination and complicated ellipse processing for setting the direction of an ellipse major axis become unnecessary. As a result, the repair time can be shortened and the cost required for repair can be suppressed.
As described above, when repairing a composite material that is damaged in the entire thickness direction, it can be repaired without disassembling the structure even if there is no space for the operator on the back side. .

本発明の複合材の修理方法においては、除去ステップでは、複合材の錐台状の範囲のうち頂面から投影領域までの範囲を除去し、支持壁に封止板を設置した後に、錐台状の範囲のうち残部を除去することが好ましい。
こうすると、封止板の表面が工具のガイド面となるので、加工が容易となる。
In the composite material repair method of the present invention, in the removing step, the range from the top surface to the projection region is removed from the frustum-shaped range of the composite material, and after the sealing plate is installed on the support wall, the frustum It is preferable to remove the remainder of the shape range.
If it carries out like this, since the surface of a sealing board will become a guide surface of a tool, processing will become easy.

本発明の複合材の修理方法では、支持壁には、裏面側から表面側に向けて拡径する錐台状の支持壁斜面を形成し、封止板には、支持壁斜面に対向する封止板斜面を形成することもできる。
これによれば、封止板および支持壁の斜面によって、複合材に生じる応力を分散させることができる。これにより、応力確保のために封止板をあまり薄くできず、そのためにスカーフ・ジョイントされる複合材および修理材の接着面の高さを十分に確保できない場合であっても、応力集中を回避できる。
In the method for repairing a composite material of the present invention, a frustum-shaped support wall slope that increases in diameter from the back surface side to the front surface side is formed on the support wall, and the sealing plate is sealed against the support wall slope. A stop plate slope can also be formed.
According to this, the stress which arises in a composite material can be disperse | distributed with the slope of a sealing plate and a support wall. As a result, the sealing plate cannot be made very thin to ensure stress, and therefore even if the height of the bonding surface of the composite material and repair material to be scarf-joined cannot be secured sufficiently, stress concentration is avoided. it can.

本発明の複合材の修理方法において、除去ステップでは、複合材の錐台状の範囲を除去するとともに、除去により形成される錐台状の貫通孔の裏面側の周縁部を支持壁とすることもできる。
このようにすると、支持壁と、複合材および修理材の接着面とをスカーフ加工によって一度に形成できるので、修理を容易化できる。
In the composite material repairing method of the present invention, in the removing step, the frustum-shaped range of the composite material is removed, and the peripheral edge portion on the back surface side of the frustum-shaped through hole formed by the removal is used as a support wall. You can also.
If it does in this way, since a support wall and the adhesion surface of a composite material and a repair material can be formed at once by scarf processing, repair can be facilitated.

本発明は、修理された複合材としても成立する。
本発明の複合材は、繊維および樹脂により板状に形成されるとともに、厚み方向に形成される貫通孔に配置される修理材と接着されることにより修理された複合材である。
本発明は、貫通孔内には、裏面側から表面側に向けて拡径する錐台状の修理材と、修理材の頂面に表面が対向する封止板と、が配置され、封止板は、それよりも裏面側で複合材に一体に形成される支持壁に設置されることで、貫通孔の裏面側を封止していることを特徴とする。
The present invention is also established as a repaired composite material.
The composite material of the present invention is a composite material repaired by being bonded to a repair material disposed in a through-hole formed in the thickness direction while being formed into a plate shape with fibers and a resin.
In the present invention, a frustum-shaped repair material whose diameter increases from the back surface side to the front surface side and a sealing plate whose surface faces the top surface of the repair material are disposed in the through hole, and sealed. The plate is characterized in that the back surface side of the through hole is sealed by being installed on a support wall formed integrally with the composite material on the back surface side.

本発明の複合材では、支持壁には、裏面側から表面側に向けて拡径する錐台状の支持壁斜面が形成され、封止板には、支持壁斜面に対向する封止板斜面が形成されていることが好ましい。   In the composite material of the present invention, the support wall is formed with a frustum-shaped support wall slope that increases in diameter from the back side to the front side, and the sealing plate has a sealing plate slope that faces the support wall slope. Is preferably formed.

以上挙げた本発明の複合材は、航空機の外板を構成することが好ましい。
航空機の翼や胴体は、外板と、外板を内側から支持する支持部材とを備えている。翼や胴体の内部は、支持部材や、燃料タンク、各種の装置などがあるため、外板の修理を内側から行うのが難しい。したがって、本発明の複合材が航空機の外板に用いられると、片側のみからのアクセスで修理を実現できる本発明の効果が際立つ。
It is preferable that the composite material of the present invention described above constitutes an outer panel of an aircraft.
An aircraft wing or fuselage includes a skin and a support member that supports the skin from the inside. Since there are support members, fuel tanks and various devices inside the wings and fuselage, it is difficult to repair the outer plate from the inside. Therefore, when the composite material of the present invention is used for an outer panel of an aircraft, the effect of the present invention in which repair can be realized by access from only one side stands out.

本発明の修理方法によれば、複合材の厚み方向全体に損傷が及んでいる場合の片側からのアクセスによる現実的な修理方法を提供できる。
また、本発明の複合材もまた、同様の効果を享受できる。
According to the repair method of the present invention, it is possible to provide a realistic repair method by accessing from one side when the entire thickness direction of the composite material is damaged.
The composite material of the present invention can also enjoy the same effect.

第1実施形態に係る複合材の修理方法の各ステップを示すフローチャートである。It is a flowchart which shows each step of the repair method of the composite material which concerns on 1st Embodiment. 複合材の修理ステップを示す断面図である。It is sectional drawing which shows the repair step of a composite material. 複合材の修理ステップを示す断面図である。It is sectional drawing which shows the repair step of a composite material. 修理された複合材を示す断面図である。It is sectional drawing which shows the repaired composite material. 第2実施形態に係る複合材の修理方法および修理された複合材を示す断面図である。It is sectional drawing which shows the repair method of the composite material which concerns on 2nd Embodiment, and the repaired composite material.

以下、添付図面に示す実施形態に基づいて本発明を詳細に説明する。
〔第1実施形態〕
損傷した複合材を片側(表面側)からのアクセスにより修理する方法、および修理された複合材について説明する。
修理対象である複合材10は、CFRPのシートが複数積層されて構成されている。CFRPの代わりに、ガラス繊維強化樹脂(GFRP:glass fiber reinforced plastics)等の繊維強化樹脂を用いることもできる。
この複合材10は、航空機の主翼や尾翼の外表面をなす外板を形成しており、スパーやリブと共にボックス状に組み立てられて構造体を構成している。
その修理は、構造体を分解せずに行われる。
まず、図1に示すように、複合材10の損傷部11を超音波探傷によって検査する(ステップS1)。超音波探傷は、公知の装置および手法により、複合材10の表面10A側(ボックスの外側)から行うことができる。
Hereinafter, the present invention will be described in detail based on embodiments shown in the accompanying drawings.
[First Embodiment]
A method of repairing a damaged composite material by access from one side (surface side) and the repaired composite material will be described.
The composite material 10 to be repaired is formed by laminating a plurality of CFRP sheets. Instead of CFRP, fiber reinforced resin such as glass fiber reinforced plastics (GFRP) can be used.
This composite material 10 forms an outer plate that forms the outer surface of the main wing or tail wing of an aircraft, and is assembled in a box shape together with spars and ribs to constitute a structure.
The repair is done without disassembling the structure.
First, as shown in FIG. 1, the damaged portion 11 of the composite material 10 is inspected by ultrasonic flaw detection (step S1). Ultrasonic flaw detection can be performed from the surface 10A side (outside the box) of the composite material 10 by a known apparatus and method.

損傷部11には、図2(a)に模式的に示すように層間が剥離した箇所が複数存在する。その剥離が存在する範囲が上記の検査により特定される。その範囲は、表面10A側を底面とする円錐台状(一点鎖線で示す)に除去される。この円錐台30の範囲内に、層間剥離が存在する範囲の全体が含まれ、かつ複合材10に作用しうる応力に耐えるように、検査結果に応じて、修理設計を行う。具体的には、円錐台の底面31の径D1と、底面31に対向する頂面32の径D2と、底面31と頂面32とを繋ぐ斜面33が底面31に対してなす傾斜角度θとを設計する。これらの底面径D1、頂面径D2、および傾斜角度θは、後述する支持壁14および封止板15の厚みT(図4)をも考慮して設計される。   The damaged portion 11 has a plurality of portions where the layers are separated as schematically shown in FIG. The range in which the peeling exists is specified by the above inspection. The range is removed in a truncated cone shape (indicated by a one-dot chain line) having the bottom surface on the surface 10A side. The entire range where the delamination exists is included in the range of the truncated cone 30 and the repair design is performed according to the inspection result so as to withstand the stress that can act on the composite material 10. Specifically, the diameter D 1 of the bottom surface 31 of the truncated cone, the diameter D 2 of the top surface 32 facing the bottom surface 31, and the inclination angle θ formed by the inclined surface 33 connecting the bottom surface 31 and the top surface 32 with respect to the bottom surface 31. To design. The bottom surface diameter D1, the top surface diameter D2, and the inclination angle θ are designed in consideration of the thickness T (FIG. 4) of the support wall 14 and the sealing plate 15 described later.

ここで、損傷部11が複合材10の裏面10B側まで及んでいる場合、それを除去するため、複合材10の表面10A側から、裏面10Bまで貫通するすり鉢状の凹部を形成することとなる。
本実施形態では、片側からのアクセスによる修理を実現するために、先ず、複合材10を厚み方向に貫通し、円錐台頂面32の径D2に相当する開口径Dの貫通孔12を複合材10の表面10A側から形成することで、損傷部11の一部を除去する。このとき、貫通孔12の裏面10B側では、径方向内側に突出する支持壁14を除去せずに残すことで、支持壁14を複合材10に一体に形成する(ステップS2および図2(b))。それにより、複合材10に円錐台30を仮定したときの頂面32から、底面31上の頂面32の投影領域までの範囲が除去される。
Here, when the damaged portion 11 extends to the back surface 10B side of the composite material 10, in order to remove it, a mortar-shaped recess penetrating from the front surface 10A side of the composite material 10 to the back surface 10B is formed. .
In the present embodiment, in order to realize repair by access from one side, first, the composite material 10 is penetrated in the thickness direction, and the through hole 12 having an opening diameter D corresponding to the diameter D2 of the truncated cone top surface 32 is formed. 10 from the surface 10A side, a part of the damaged portion 11 is removed. At this time, on the back surface 10B side of the through hole 12, the support wall 14 protruding inward in the radial direction is left without being removed, so that the support wall 14 is formed integrally with the composite material 10 (step S2 and FIG. 2B). )). Thereby, the range from the top surface 32 when the truncated cone 30 is assumed to the composite material 10 to the projection region of the top surface 32 on the bottom surface 31 is removed.

支持壁14は、貫通孔12の全周に亘り、内形および外形が真円の環状に形成されている。支持壁14の裏面は、複合材10の裏面10Bに連続している。この支持壁14および次に示す封止板15の厚みは、後述する凹部斜面18を出来るだけ広く確保するため、複合材10の厚みに対して極力薄くするのが好ましい。その一方で、支持壁14および封止板15には、真空引きに耐える強度が得られる程度の厚みを確保する。
支持壁14の径方向の幅は、裏面10B近傍の損傷部11を除去でき、かつ真空引き時に封止板15を押さえられる限り、任意である。
The support wall 14 is formed in an annular shape having an inner shape and an outer shape over the entire circumference of the through hole 12. The back surface of the support wall 14 is continuous with the back surface 10 </ b> B of the composite material 10. The thickness of the support wall 14 and the sealing plate 15 shown below is preferably as thin as possible with respect to the thickness of the composite material 10 in order to ensure a concave slope 18 described later as wide as possible. On the other hand, the support wall 14 and the sealing plate 15 are secured to such a thickness that the strength to withstand vacuuming can be obtained.
The width of the support wall 14 in the radial direction is arbitrary as long as the damaged portion 11 in the vicinity of the back surface 10B can be removed and the sealing plate 15 can be pressed during evacuation.

貫通孔12および支持壁14の加工方法は任意である。例えば、支持壁14の内径に対向する開口径の孔を複合材10の厚み全体に貫通して形成した後、その孔を支持壁14が形成される部分を除いては開口径Dまで拡げることにより、貫通孔12および支持壁14を形成することができる。あるいは、支持壁14の内径に対応する範囲のみを穿孔する刃と、その刃よりも穿孔方向の後方に位置し、開口径Dで穿孔する刃とを有する工具を用いて、一度の孔明け加工で貫通孔12および支持壁14を形成することもできる。   The processing method of the through-hole 12 and the support wall 14 is arbitrary. For example, after forming a hole having an opening diameter facing the inner diameter of the support wall 14 through the entire thickness of the composite material 10, the hole is expanded to the opening diameter D except for a portion where the support wall 14 is formed. Thus, the through hole 12 and the support wall 14 can be formed. Alternatively, once drilling is performed using a tool having a blade that drills only a range corresponding to the inner diameter of the support wall 14 and a blade that is positioned behind the blade in the drilling direction and drills with an opening diameter D. The through hole 12 and the support wall 14 can also be formed.

次に、表面10A側から貫通孔12内に、貫通孔12の開口径Dと同等の径とされる真円の封止板15を挿入し、貫通孔12の奥に(裏面10B側に)設置する(ステップS3および図2(c))。封止板15は、支持壁14の表面に支持される。
この封止板15は、後述する真空引きにあたって裏面10B側を封止するために用いられる。封止板15は、複合材10を構成するのと同様のCFRPのシートにより構成されている。封止板15の厚みに応じて、封止板15には1枚以上のCFRPシートが用いられる。
封止板15は、貫通孔12に挿入される前に封止板15の裏面側の周縁部に塗布される接着剤(図示せず)によって支持壁14の表面に接着される。これにより、封止板15と支持壁14との間の隙間が封止される。
Next, a perfect circular sealing plate 15 having a diameter equivalent to the opening diameter D of the through hole 12 is inserted into the through hole 12 from the front surface 10A side, and the back of the through hole 12 (on the back surface 10B side). Installation (step S3 and FIG. 2 (c)). The sealing plate 15 is supported on the surface of the support wall 14.
This sealing plate 15 is used for sealing the back surface 10B side in vacuuming described later. The sealing plate 15 is composed of a CFRP sheet similar to that constituting the composite material 10. Depending on the thickness of the sealing plate 15, one or more CFRP sheets are used for the sealing plate 15.
The sealing plate 15 is adhered to the surface of the support wall 14 by an adhesive (not shown) applied to the peripheral portion on the back surface side of the sealing plate 15 before being inserted into the through hole 12. Thereby, the gap between the sealing plate 15 and the support wall 14 is sealed.

続いて、スカーフ加工により、円錐台30の範囲のうち損傷部11が残存する残部を削り取って損傷部11全体を除去する(ステップS4および図3(a))。このスカーフ加工は、複合材10と、後述する修理材20とが接着される面積を拡大し、それらの接着部の応力集中を緩和するため、封止板15の表面15Aの周縁近傍から、複合材10の表面10A側に向けて拡がる凹部斜面18を形成する。スカーフ加工は、複合材10の表面10A側から、封止板15の表面15Aの位置まで行う。封止板15の表面15Aは工具のガイド面となる。
凹部斜面18は、裏面10Bに対して上述の傾斜角度θで傾斜している。傾斜角度θは、上述のように、損傷部11の範囲と、複合材10に作用しうる応力によって定められ、例えば、複合材10の厚み1に対して凹部斜面18の半径が10〜30に設定される。
この凹部斜面18により、貫通孔12よりも容積が拡大されたすり鉢状の貫通凹部13が形成される。凹部斜面18は、複合材10の厚み全体から、支持壁14および封止板15の厚みT(図4)を引いた範囲に形成されている。
Subsequently, by scarf processing, the remaining part where the damaged part 11 remains in the range of the truncated cone 30 is scraped off to remove the entire damaged part 11 (step S4 and FIG. 3A). This scarf processing is performed from the vicinity of the periphery of the surface 15A of the sealing plate 15 in order to enlarge the area where the composite material 10 and the repair material 20 described later are bonded and to relieve stress concentration at the bonded portion. A concave slope 18 that extends toward the surface 10A side of the material 10 is formed. The scarf processing is performed from the surface 10A side of the composite material 10 to the position of the surface 15A of the sealing plate 15. The surface 15A of the sealing plate 15 serves as a guide surface for the tool.
The concave slope 18 is inclined at the aforementioned inclination angle θ with respect to the back surface 10B. As described above, the inclination angle θ is determined by the range of the damaged portion 11 and the stress that can act on the composite material 10. For example, the radius of the concave slope 18 is 10 to 30 with respect to the thickness 1 of the composite material 10. Is set.
The concave slope 18 forms a mortar-shaped through recess 13 whose volume is larger than that of the through hole 12. The concave slope 18 is formed in a range obtained by subtracting the thickness T (FIG. 4) of the support wall 14 and the sealing plate 15 from the entire thickness of the composite material 10.

そして、貫通凹部13に、複合材10の製造時に用いるのと同様のプリプレグである修理材20を配置する(ステップS5および図3(b))。プリプレグは、シート状とされる炭素繊維をエポキシ樹脂、ポリイミド等の半硬化の熱硬化性樹脂に含浸させた中間素材であり、樹脂が硬化していないために加工が容易で、かつ製造時に繊維および樹脂の配合量が一定に管理されることで性状が安定し、均質性の点で品質が高い。乾式法、湿式法のいずれで作製されたプリプレグをも用いることができる。なお、封止板15には、プリプレグを硬化させたものが用いられる。
修理材20は、貫通凹部13の形状に対応する円錐台形状とされ、その底面径、頂面径、および傾斜角度は、上述の底面径D1、頂面径D2、および傾斜角度θと同等とされている。複合材10の表面10Aと修理材20の表面20Aとは実質的に面一とされる。
修理材20には、硬化後に複合材10と同等の強度を発揮するプリプレグが選定される。修理材20と複合材10(母材)との境界に応力集中が生じるのを避けるためである。
複合材10の凹部斜面18とそれに対向する修理材20の斜面20Cとの間、および封止板15の表面15Aとそれに対向する修理材20の裏面20Bとの間には、熱硬化性樹脂から形成されたフィルム等(図示せず)が複合材10と修理材20とを接着するための接着剤AD(図4)として配置される。複合材10と修理材20との接着の用をなす限り、接着剤ADの形態や性状は問わない。
And the repair material 20 which is the same prepreg as used at the time of manufacture of the composite material 10 is arrange | positioned in the penetration recessed part 13 (step S5 and FIG.3 (b)). A prepreg is an intermediate material made by impregnating a sheet-like carbon fiber with a semi-cured thermosetting resin such as epoxy resin or polyimide, and is easy to process because the resin is not cured. In addition, the property is stabilized by controlling the blending amount of the resin to be constant, and the quality is high in terms of homogeneity. A prepreg produced by either a dry method or a wet method can also be used. For the sealing plate 15, a cured prepreg is used.
The repair material 20 has a truncated cone shape corresponding to the shape of the through recess 13, and its bottom surface diameter, top surface diameter, and inclination angle are the same as the above-described bottom surface diameter D1, top surface diameter D2, and inclination angle θ. Has been. The surface 10A of the composite material 10 and the surface 20A of the repair material 20 are substantially flush with each other.
A prepreg that exhibits the same strength as the composite material 10 after curing is selected as the repair material 20. This is to avoid stress concentration at the boundary between the repair material 20 and the composite material 10 (base material).
Between the concave slope 18 of the composite material 10 and the slope 20C of the repair material 20 facing it, and between the surface 15A of the sealing plate 15 and the back surface 20B of the repair material 20 facing it, thermosetting resin is used. A formed film or the like (not shown) is disposed as an adhesive AD (FIG. 4) for bonding the composite material 10 and the repair material 20. As long as the composite material 10 and the repair material 20 are used for bonding, the form and properties of the adhesive AD are not limited.

次に、図示しない真空ポンプを用いて真空引きを行う(ステップS6および図3(c))。このとき、修理材20の表面20Aおよびその周囲は耐熱性のバックフィルム21で覆われる。修理材20の表面20Aの周囲に配置されるシーラントテープ22により、バックフィルム21と複合材10の表面10Aとの間が封止される。シーラントテープ22は、耐熱性および密着性を有するシーラント材料から紐状に形成されており、表面10A上で修理材20を取り囲むように環状に配置されている。   Next, vacuuming is performed using a vacuum pump (not shown) (step S6 and FIG. 3C). At this time, the surface 20 </ b> A of the repair material 20 and its periphery are covered with a heat-resistant back film 21. The space between the back film 21 and the surface 10 </ b> A of the composite material 10 is sealed by the sealant tape 22 disposed around the surface 20 </ b> A of the repair material 20. The sealant tape 22 is formed in a string shape from a sealant material having heat resistance and adhesion, and is arranged in an annular shape so as to surround the repair material 20 on the surface 10A.

真空ポンプを動作させると、バックフィルム21に設けられる真空バルブ23を介して、バックフィルム21と封止板15とで挟まれた複合材10と修理材20との間の隙間が減圧される。このとき、大気圧との差圧により、封止板15が支持壁14で押圧されるので、バックフィルム21と封止板15とによる封止を維持できる。しかも、封止板15は、複合材10と同様の材料から形成されることにより、強度が高く、強度均一性の観点から高い品質とされているので、吸引時に変形せずに、隙間に均一な圧力を作用させながら、所望の真空度にまで減圧できる。これにより、複合材10と修理材20との互いの対向面を、接着剤ADを挟んで均一に密着させることができるので、高い接着品質が得られる。
なお、真空バルブ23は、未硬化の修理材20の表面20Aが真空バルブ23により押圧されて陥没するのを避けるため、修理材20の表面20Aの外周縁と、シーラントテープ22との間に位置する複合材10上に設けられている。
When the vacuum pump is operated, the gap between the composite material 10 and the repair material 20 sandwiched between the back film 21 and the sealing plate 15 is decompressed via the vacuum valve 23 provided in the back film 21. At this time, since the sealing plate 15 is pressed by the support wall 14 due to the pressure difference from the atmospheric pressure, the sealing by the back film 21 and the sealing plate 15 can be maintained. Moreover, since the sealing plate 15 is formed of the same material as the composite material 10 and has high strength and high quality from the viewpoint of strength uniformity, it is uniform in the gap without being deformed during suction. The pressure can be reduced to a desired degree of vacuum while applying an appropriate pressure. Thereby, since the mutually opposing surface of the composite material 10 and the repair material 20 can be made to closely_contact | adhere on both sides of adhesive agent AD, high adhesive quality is obtained.
The vacuum valve 23 is positioned between the outer peripheral edge of the surface 20A of the repair material 20 and the sealant tape 22 in order to prevent the surface 20A of the uncured repair material 20 from being depressed by the vacuum valve 23. It is provided on the composite material 10 to be made.

その後、適宜な加熱手段により、修理材20および接着剤ADを加熱して硬化させる(ステップS7および図3(d))。このステップでも、真空引きを継続するのが好ましい。
本実施形態では、ヒータを内蔵するヒータマット24をバックフィルム21上に配置して加熱する。加熱手段として、他の形態のヒータやドライヤーを用いることもできる。加熱手段は、熱の伝搬方式を問わず、任意に構成できる。修理対象の構造体をオーブンに入れて加熱することもできる。
修理材20および接着剤ADが硬化すると、複合材10に修理材20が接着される。真空引きにより複合材10と修理材20とが均一に密着しているので、均一な接着強度で両者は強固に一体化される。
以上の手順により、複合材10の修理を完了する。上述した修理の各ステップは、いずれも複合材10の表面10A側から行われる。
図4に、修理された複合材10を示す。
Thereafter, the repair material 20 and the adhesive AD are heated and cured by appropriate heating means (step S7 and FIG. 3D). Even in this step, it is preferable to continue evacuation.
In the present embodiment, a heater mat 24 incorporating a heater is disposed on the back film 21 and heated. Other types of heaters and dryers can be used as the heating means. The heating means can be arbitrarily configured regardless of the heat propagation method. The structure to be repaired can also be heated in an oven.
When the repair material 20 and the adhesive AD are cured, the repair material 20 is bonded to the composite material 10. Since the composite material 10 and the repair material 20 are in close contact with each other by evacuation, the two are firmly integrated with uniform adhesive strength.
The repair of the composite material 10 is completed by the above procedure. Each of the repair steps described above is performed from the surface 10A side of the composite material 10.
FIG. 4 shows the repaired composite material 10.

本実施形態の修理方法では、損傷部11の除去により形成される貫通凹部13の裏面10B側に支持壁14を形成しておき、そこに設置される封止板15によって貫通凹部13の裏面10B側を封止している。このため、貫通凹部13の裏面10B側を封止するために、従来手法のように楕円形状の貫通凹部を形成し、その貫通凹部に挿入したパッチを裏面10Bに貼り付ける必要がない。このため、貫通凹部13の平面形状は、汎用的な加工で足りる真円とされている。それにより、楕円長軸の向きを設定するための強度検討や繁雑な楕円加工が不要となるので、修理時間を短縮できるとともに、修理に要するコストを抑えられる。
また、本実施形態では、支持壁14の表面側に封止板15が支持されるので、従来手法のようにパッチを裏面側にもぐらせるときの脱落を防ぐため、パッチを吊り下げておくのも不要となる。しかも、支持壁14の表面および貫通孔12の内壁によって封止板15を位置決めできる。これにより、修理作業が容易となる。
In the repair method of this embodiment, the support wall 14 is formed on the back surface 10B side of the through recess 13 formed by removing the damaged portion 11, and the back surface 10B of the through recess 13 is formed by the sealing plate 15 installed there. The side is sealed. For this reason, in order to seal the back surface 10B side of the through recess 13, it is not necessary to form an elliptical through recess as in the conventional method and attach the patch inserted into the through recess to the back surface 10B. For this reason, the planar shape of the penetration recessed part 13 is made into the perfect circle which needs a general-purpose process. This eliminates the need for strength examination and complicated ellipse processing for setting the orientation of the ellipse major axis, thereby reducing the repair time and reducing the cost required for repair.
In this embodiment, since the sealing plate 15 is supported on the front surface side of the support wall 14, the patch is suspended in order to prevent dropping when the patch is moved to the back surface side as in the conventional method. Is also unnecessary. In addition, the sealing plate 15 can be positioned by the surface of the support wall 14 and the inner wall of the through hole 12. This facilitates repair work.

以上説明した本実施形態によれば、裏面10B側(構造体の内部)に作業者が入れるスペースがなくても、支障なく修理できる。したがって、構造体を分解することなく、複合材10の全面に亘って、片側(表面側)からのアクセスによる修理を実現できる。分解が不要なことで、コストを抑えて修理を実施できる。
本実施形態の修理方法によって修理された複合材10もまた、以上で述べた効果を享受できる。
According to this embodiment described above, even if there is no space for the operator to enter on the back surface 10B side (inside the structure), it can be repaired without any trouble. Therefore, repair by access from one side (surface side) can be realized over the entire surface of the composite material 10 without disassembling the structure. Since disassembly is unnecessary, repairs can be carried out at a reduced cost.
The composite material 10 repaired by the repair method of the present embodiment can also enjoy the effects described above.

なお、損傷部11の検査結果に応じて、底面径D1、頂面径D2、および傾斜角度θをその都度設計する代わりに、損傷部11の寸法形状や、応力について複数に定形化し、各定形に適合する底面径D1、頂面径D2、および傾斜角度θの一式を複数パターン用意しておくこともできる。それにより、損傷部11の検査結果をいずれかのパターンにあてはめれば足りるので、修理に係る設計が容易となる。   In addition, instead of designing the bottom surface diameter D1, the top surface diameter D2, and the inclination angle θ each time according to the inspection result of the damaged portion 11, the dimensional shape and stress of the damaged portion 11 are standardized into a plurality of shapes. It is also possible to prepare a plurality of patterns of a set of bottom surface diameter D1, top surface diameter D2, and inclination angle θ suitable for the above. As a result, it is sufficient to apply the inspection result of the damaged portion 11 to any one of the patterns, so that the design for repair is facilitated.

〔第2実施形態〕
次に本発明の第2実施形態ついて図5を参照して説明する。
第2実施形態では、第1実施形態との相違点を中心に説明し、第1実施形態と同様の構成については同じ符号を付して説明を省略する。
図5(a)に示すように、本実施形態では、封止板15の封止板斜面151を裏面10Bに対して傾斜させるとともに、封止板斜面151に倣う支持壁斜面141を支持壁14に形成している。
本実施形態の貫通凹部13は、第1斜面としての凹部斜面18と、第2斜面としての支持壁斜面141とにより形成されている。
支持壁斜面141および封止板斜面151は、貫通凹部13の裏面10B側から表面10A側に向けて拡径している。裏面10Bに対する支持壁斜面141および封止板斜面151の傾斜角度は、貫通凹部13の凹部斜面18の傾斜角度とは必ずしも一致しない。また、封止板斜面151と凹部斜面18とは連続していなくてもよく、図5の例では、支持壁斜面141と凹部斜面18との間に、裏面10Bと平行な面17が介在している。
一方、封止板斜面151と凹部斜面18とを同一の傾斜角度で連続させることもできる。この場合、除去ステップS2では、複合材10の円錐台状の範囲を除去するとともに、それにより形成される貫通凹部13の裏面10B側の周縁部を支持壁14とする。こうすると、支持壁14および貫通凹部13をスカーフ加工によって一度に形成できるので、修理を容易化できる。
[Second Embodiment]
Next, a second embodiment of the present invention will be described with reference to FIG.
In the second embodiment, the difference from the first embodiment will be mainly described, and the same components as those in the first embodiment will be denoted by the same reference numerals and the description thereof will be omitted.
As shown in FIG. 5A, in this embodiment, the sealing plate slope 151 of the sealing plate 15 is inclined with respect to the back surface 10B, and the support wall slope 141 that follows the sealing plate slope 151 is formed on the support wall 14. Is formed.
The through recess 13 of the present embodiment is formed by a recess slope 18 as a first slope and a support wall slope 141 as a second slope.
The support wall slope 141 and the sealing plate slope 151 are expanded in diameter from the back surface 10B side of the through recess 13 toward the front surface 10A side. The inclination angles of the support wall inclined surface 141 and the sealing plate inclined surface 151 with respect to the back surface 10B do not necessarily coincide with the inclined angle of the recessed portion inclined surface 18 of the through recess 13. Further, the sealing plate slope 151 and the recess slope 18 may not be continuous. In the example of FIG. 5, a surface 17 parallel to the back surface 10 </ b> B is interposed between the support wall slope 141 and the recess slope 18. ing.
On the other hand, the sealing plate slope 151 and the concave slope 18 can be made continuous at the same tilt angle. In this case, in the removal step S <b> 2, the frustoconical range of the composite material 10 is removed, and the peripheral edge portion on the back surface 10 </ b> B side of the through recess 13 formed thereby is used as the support wall 14. If it carries out like this, since the support wall 14 and the penetration recessed part 13 can be formed at once by a scarf process, repair can be made easy.

第2実施形態では、第1実施形態と同様の手順により、複合材10に支持壁14を形成し、さらに支持壁14に支持壁斜面141を形成する。そして、封止板斜面151が形成された封止板15を支持壁14上に設置すると、図5(a)に示すように、支持壁斜面141に封止板斜面151が対向する。
その後、第1実施形態と同様に、スカーフ加工によって形成した貫通凹部13の内側に修理材20を配置し、真空引き、加熱および硬化のステップを経ると、図5(b)に示すように修理が完了する。
そのように修正された複合材10は、支持壁斜面141および封止板斜面151によって、複合材10に生じる応力を分散させることができる。これにより、応力確保のために封止板15をあまり薄くできず、スカーフ・ジョイントされる複合材10および修理材20の接着面(凹部斜面18)の高さを十分に確保できない場合であっても、支持壁斜面141および凹部斜面18の全体でなす応力分散により、応力集中を回避できる。
In the second embodiment, the support wall 14 is formed on the composite material 10 and the support wall slope 141 is formed on the support wall 14 by the same procedure as in the first embodiment. When the sealing plate 15 on which the sealing plate slope 151 is formed is installed on the support wall 14, the sealing plate slope 151 faces the support wall slope 141 as shown in FIG.
After that, as in the first embodiment, the repair material 20 is arranged inside the through recess 13 formed by scarf processing, and after the steps of evacuation, heating, and curing, the repair is performed as shown in FIG. 5B. Is completed.
The composite material 10 so modified can disperse the stress generated in the composite material 10 by the support wall slope 141 and the sealing plate slope 151. This is a case where the sealing plate 15 cannot be made too thin to secure stress, and the height of the bonding surface (the concave slope 18) of the composite material 10 and the repair material 20 to be scarf-joined cannot be sufficiently secured. However, stress concentration can be avoided by the stress distribution formed by the entire support wall slope 141 and the concave slope 18.

上記以外にも、本発明の主旨を逸脱しない限り、上記実施形態で挙げた構成を取捨選択したり、他の構成に適宜変更することが可能である。
例えば、上記の修理手順では、貫通孔12の裏面10B側に封止板15を設置した後に、スカーフ加工を行っているが、貫通孔12の形成に続いてスカーフ加工を行ってから、封止板15を設置することもできる。その場合に、封止板15と修理材20とを予め一体化しておいたものを貫通凹部13に配置するようにしてもよい。
また、貫通凹部13に配置される修理材は、上記の修理材20には限定されない。その修理材は、繊維と、溶融状態の樹脂とで構成することもできる。その繊維を貫通凹部13に配置し、貫通凹部13内に溶融樹脂を流し入れることで繊維を樹脂に含浸させればよい。
上記各実施形態では、支持壁14は周方向に連続して環状に形成されているが、本発明は、支持壁を周方向に不連続な形状とすることも許容する。
本発明における支持壁および封止板は、真空引きに際して封止の用をなす限り、その具体的な形状を問わない。
さらに、本発明における「錐台」には、上記実施形態で開示した円錐台のみならず、楕円錐台なども含まれる。
なお、本発明における複合材は、航空機の翼の外板に限らず、種々の構造に適用できる。中でも、風車の翼は、航空機の翼と同様、ボックス状に組み立てられるので、その風車翼の外板に好適である。
In addition to the above, as long as the gist of the present invention is not deviated, the configuration described in the above embodiment can be selected or changed to another configuration as appropriate.
For example, in the above repair procedure, the scarf processing is performed after the sealing plate 15 is installed on the back surface 10B side of the through hole 12, but the sealing is performed after the scarf processing is performed following the formation of the through hole 12. A plate 15 can also be installed. In that case, the sealing plate 15 and the repair material 20 integrated in advance may be disposed in the through recess 13.
Further, the repair material disposed in the through recess 13 is not limited to the repair material 20 described above. The repair material can also be composed of fibers and molten resin. The fiber may be disposed in the through recess 13 and the resin may be impregnated with the resin by pouring molten resin into the through recess 13.
In each of the above-described embodiments, the support wall 14 is formed in an annular shape continuously in the circumferential direction. However, the present invention allows the support wall to have a discontinuous shape in the circumferential direction.
The support wall and the sealing plate in the present invention may be of any specific shape as long as they are used for sealing during evacuation.
Furthermore, the “frustum” in the present invention includes not only the truncated cone disclosed in the above embodiment but also an elliptical truncated cone.
In addition, the composite material in this invention is applicable not only to the outer plate | board of an aircraft wing but to various structures. Especially, since the wing | blade of a windmill is assembled in a box shape similarly to the wing | blade of an aircraft, it is suitable for the outer plate | board of the windmill blade.

10 複合材
10A 表面
10B 裏面
11 損傷部
12 貫通孔
13 貫通凹部(貫通孔)
14 支持壁
15 封止板
15A 表面
18 凹部斜面
20 修理材
20A 表面
20B 裏面
20C 斜面
21 バックフィルム
22 シーラントテープ
23 真空バルブ
24 ヒータマット
31 底面
32 頂面
33 斜面
141 支持壁斜面
151 封止板斜面
AD 接着剤
D 開口径
D1 底面径
D2 頂面径
θ 傾斜角度
DESCRIPTION OF SYMBOLS 10 Composite material 10A Front surface 10B Back surface 11 Damaged part 12 Through hole 13 Through recessed part (through hole)
14 Support Wall 15 Sealing Plate 15A Surface 18 Concave Slope 20 Repair Material 20A Surface 20B Backside 20C Slope 21 Back Film 22 Sealant Tape 23 Vacuum Valve 24 Heater Mat 31 Bottom 32 Top Surface 33 Slope 141 Support Wall Slope 151 Sealing Plate Slope AD Adhesive D Opening diameter D1 Bottom diameter D2 Top surface diameter θ Inclination angle

Claims (12)

繊維および樹脂により形成された板状の複合材において裏面側から表面側に向けて拡径する錐台状の範囲を除去し、前記複合材と、除去された部分に代わる修理材とを接着する修理方法であって、
前記錐台の頂面の周縁部から径方向内側に突出する支持壁を残して、前記頂面から、前記錐台の底面における前記頂面の投影領域までを含む範囲を前記表面側から厚み方向に貫通して除去する除去ステップと、
除去により形成される貫通孔に前記表面側から挿入された封止板を前記支持壁に設置することで前記裏面側を封止する裏面側封止ステップと、
前記錐台状の範囲が除去された前記複合材に、接着剤を介在させて前記修理材を配置する修理材配置ステップと、
前記表面側を封止して真空引きする真空引きステップと、を備える、
ことを特徴とする複合材の修理方法。
In the plate-like composite material formed of fiber and resin, the frustum-shaped range that expands from the back side to the front side is removed, and the composite material is bonded to the repair material in place of the removed portion. A repair method,
A thickness range from the top surface side to the projection area of the top surface on the bottom surface of the frustum from the top surface side, leaving a support wall protruding radially inward from the peripheral edge of the top surface of the frustum A removal step to penetrate through and
A back side sealing step for sealing the back side by installing a sealing plate inserted from the front side into the through hole formed by removal on the support wall;
A repair material placement step of placing the repair material with an adhesive interposed in the composite material from which the frustum-shaped area has been removed, and
Vacuuming step of sealing and vacuuming the surface side,
A method of repairing a composite material characterized by the above.
前記除去ステップでは、前記複合材の前記錐台状の範囲のうち前記頂面から前記投影領域までの範囲を除去し、
前記支持壁に前記封止板を設置した後に、前記錐台状の範囲のうち残部を除去する、
請求項1に記載の複合材の修理方法。
In the removing step, the range from the top surface to the projection region is removed from the frustum-shaped range of the composite material,
After the sealing plate is installed on the support wall, the remainder is removed from the frustum-shaped range.
The method for repairing a composite material according to claim 1.
前記支持壁には、前記裏面側から前記表面側に向けて拡径する錐台状の支持壁斜面を形成し、
前記封止板には、前記支持壁斜面に対向する封止板斜面を形成する、
請求項1または2に記載の複合材の修理方法。
The support wall is formed with a frustum-shaped support wall slope that expands from the back side toward the front side,
Forming a sealing plate slope opposite to the support wall slope on the sealing plate;
The repair method of the composite material of Claim 1 or 2.
前記除去ステップでは、前記複合材の前記錐台状の範囲を除去するとともに、除去により形成される前記錐台状の貫通孔の前記裏面側の周縁部を前記支持壁とする、
請求項3に記載の複合材の修理方法。
In the removing step, the frustum-shaped range of the composite material is removed, and the peripheral portion on the back surface side of the frustum-shaped through hole formed by the removal is used as the support wall.
The method for repairing a composite material according to claim 3.
前記貫通孔の開口径(D)は、スカーフ加工により形成される前記錐台の前記頂面の径(D2)に相当する、
請求項1から4のいずれか1項に記載の複合材の修理方法。
The opening diameter (D) of the through hole corresponds to the diameter (D2) of the top surface of the frustum formed by scarf processing.
The repair method of the composite material of any one of Claim 1 to 4.
前記支持壁は、前記複合材と一体に形成される、
請求項1から5のいずれか1項に記載の複合材の修理方法。
The support wall is formed integrally with the composite material.
The method for repairing a composite material according to any one of claims 1 to 5.
前記支持壁は、前記貫通孔の全周に亘って形成される、
請求項1から6のいずれか1項に記載の複合材の修理方法。
The support wall is formed over the entire circumference of the through hole.
The repair method of the composite material of any one of Claim 1 to 6.
前記支持壁は、内形および外形が真円の環状に形成されている、
請求項1から7のいずれか1項に記載の複合材の修理方法。
The support wall is formed in an annular shape having an inner shape and an outer shape,
The method for repairing a composite material according to any one of claims 1 to 7.
前記封止板は、少なくとも1枚のCFRPシートから構成される、
請求項1から8のいずれか1項に記載の複合材の修理方法。
The sealing plate is composed of at least one CFRP sheet.
The method for repairing a composite material according to any one of claims 1 to 8.
前記封止板斜面と前記錐台状の範囲の斜面とを、同一の傾斜角度で連続させる、
請求項3に記載の複合材の修理方法。
The sealing plate slope and the slope of the frustum-shaped range are continued at the same inclination angle,
The method for repairing a composite material according to claim 3.
前記封止板は、真円である、
請求項1から10のいずれか1項に記載の複合材の修理方法。
The sealing plate is a perfect circle,
The method for repairing a composite material according to claim 1.
前記真空引きは、前記表側からのみ行われる、
請求項1から11のいずれか1項に記載の複合材の修理方法。
The evacuation is performed only from the front side,
The method for repairing a composite material according to any one of claims 1 to 11.
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